Polymerization process



United States Patent Ofifice 3,353,056 Patented Dec. 12, 196;

3,358,056 POLYMERIZATION PROCESS Samuel Reuaudo, Bartlesville, Okla, assigior to Phillips Petroleum Company, a corporation of Delaware N Drawing. Filed June 1, 1964, Ser. No. 371,787 9 Claims. (Cl. 260878) ABSTRACT OF THE DISCLOSURE A block copolymer of ethylene and propylene is produced by a two step process. In one step the slower reacting monomer, propylene, is polymerized at a relatively high temperature in the presence of liquid propylene as the sole diluent so as to produce a propylene block at commercially acceptable rates. In the other step ethylone is polymerized at a relatively low temperature, again in the presence of liquid propylene as the sole diluent. Because of this low temperature the block produced in this step is compared predominately of ethylene. These steps may be carried out in any orderthat is the high temperature polymerization of the propylene may be either first or second.

This invention relates to a combination polymerization process for the polymerization of propylene and ethylene.

It is known to prepare an ethylene-propylene block copolymer having high crystallinity, impact strength, modllus, and tensile and low brittleness temperature by polymerizing one monomer, removing any unpolymerized material suspending the polymer in a hydrocarbon solvent such as n-heptane; and polymerizing a second monomer block onto the first polymer block.

An object of this invention is to provide new polymer products. A further object of this invention is to provide methods of preparing these products. A further object of this invention is to provide a new polymerization process in which propylene is polymerized in liquid propylene as the diluent followed by the polymerization of ethylene in the presence of the polypropylene initially formed and liquid propylene as the diluent under conditions such that a high ethylene content copolymer block is formed. A further object is to provide a polymerization process in which a mixture of ethylene and propylene is polymerized under conditions such that a high ethylene content polymer is produced, unpolymerized ethylene is removed and additional propylene polymerized in the presence of the first polymer to provide a polypropylene block thereon. Other objects and advantages of this invention will be ap parent to those skilled in the art upon reading this disclosure.

My invention constitutes an improvement over the combination process described above because no extraneous diluents are required. By proper temperature selection it is possible to carry out both steps of the polymerization using liquid propylene as the reaction medium while still obtaining good reaction rates. The use of a comparatively low temperature for the polymerization of the ethylene in the presence of liquid propylene is necessary for a high ethylene content. Generally, I prefer to carry out this step of the polymerization at -50 to 75 F. Especially good results are obtained below 10 F. Higher temperatures, as high as generally 80 to 150 F., are used for the homopolymerization of the propylene.

Broadly, then, my invention resides in a polymerization process comprising polymerizing ethylene in the presence of liquid propylene in the absence of additional liquid diluent using a catalyst active for such polymerization under conditions such that a predominantly ethylene polymer is formed. In a further aspect, the invention 7 aluminum,

resides in a two-step polymerization process comprising 1 step in which propylene as the sole monomer is polym erized in the presence of liquid propylene in the absenc of additional liquid diluent and a step in which ethylene is polymerized in the presence of liquid propylene in th absence of additional liquid diluent, the step which is carried out second being performed in the presence of the polymer produced in the first, using a catalyst active for the polymerization. In a further aspect, it comprises 2 polymerization process comprising polymerizing propylene in liquid propylene as a reaction medium in the presence of a catalyst active for such polymerization at a temperature in the range of to F., adding ethylene and continuing polymerization at a temperature below 10 F. Yet another aspect comprises a polymerization process comprising polymerizing ethylene in the presence of liquid propylene in the absence of additional liquid diluent using a catalyst active for such polymerization, removing unpolymerized ethylene from the reaction mixture, and polymerizing at least a portion of the remaining propylene in the presence of the polymer produced in the first step.

Since a wide variety of catalyst systems can be employed in the polymerization, it is not intended to limit the invention to any particular catalyst system. Catalyst systems suitable for use in the polymerization are those which are capable of polymerizing a mono-l-olefin in a mass polymerization system and under conditions such that solid polymer in particle form is produced. Catalyst systems suitable for use can be broadly defined as comprising an organometal compound and a metal salt. A particularly suitable catalyst is one which comprises (a) a compound having the formula R MX wherein R is an alkyl, cycloalkyl or aryl radical or combinations of these radicals, such as alkaryl, aralkyl and alkylcycloalkyl, X is hydrogen or a halogen, including chlorine, bromine, iodine and fluorine, M is aluminum, gallium, indium or thallium, n is from 1 to 3, inclusive, m is from zero to 2, inclusive, and the sum of m and n is equal to the valence of the metal M, and (b) a halide of a metal of Group 1VA, IV-B, V-B, VI-B or VIII. The hydrocarbon radicals which can be substituted for R in the aforementioned formula include radicals having up to about 20 carbon atoms each. Radicals having 10 carbon atoms or less are preferred since the resulting catalyst composition has .a greater activity for initiating the polymerization.

Examples of compounds corresponding to the formula R MX which canbe employed include trimethylaluminum, triethylaluminum, triisobutylaluminum, tri-n-butyltri-n-pentylaluminum, triisooctylaluminum, tri-n-dodecylaluminum, triphenylaluminum, triethylgallium, triphenylgallium, tricyclohexylgallium, tri-n-butylindium, triethylthallium, diethylaluminum hydride,

(cyclohexane derivative), (C H )GaBr (benzene derivatlVC), C20H4 GaBI'2, (C14H29)2G3F, (C6H5)2II1C1 (bellzene derivative), cgH qInFz, (C H flnBr (cyclohexane derivative), 3-methylcyclohexylaluminum dichloride, 2- cyclohexylethylgallium dichloride, p-tolylberyllium iodide, di-(3-phenyl-l-methylpropyl) indium fluoride, 2-(3-isopropylcyclohexyl)ethylthallium dibromide, and the like. Mixtures of these materials, such as a mixture of diethylaluminum chloride and ethylaluminum dichloride, etc., can also be employed.

The metal halide component of the catalyst system is preferably a halide of a Group IV-A or IV-B metal, i.e.,

titanium, zirconium, hafnium and germanium. The trichlorides, trifiuorides, tribromides, and triiodides, as well as the tetrachloride, tetrafiuorides, tetrabromides and :traiodides of the Group IV-A or 1VB metals, can be sed in the catalyst system, either individually or as mix- .1168 of two or more of the metal halides. It is usually referred to employ a trichloride, such as titanium trihloride, in the polymerization. However, it is to be un- .erstoo-d that halides of metals of the other groups speci- ;ed above, such as vanadium, molybdenum, tungsten, :obalt, and iron can also be employed in the catalyst ystem.

The preferred catalyst system employed in the polymrization comprises a dialkylaluminum chloride, such as liethylaluminum chloride, and titanium trichloride, the atter compound preferably being prepared by reduction )f titanium tetrachloride in the presence of aluminum. Fhe reduction product is preferably a complex having the ipproximate formula 3TiCl .AlCl The reduction reacion is usually carried out at an elevated temperature, for :xample, at a temperature in the range of 360 to 600 F., preferably from 375 to 450 F.

The amount of catalyst employed in the polymeriza- ;ion can vary over a rather wide range and will depend at least to a certain degree upon the particular catalyst system utilized. However, the determination of the actual amount of the catalyst employed in any particular polymerization is well within the skill of the art. In general, the mol ratio of the organometal compound to the metal salt falls within the range of 0.02 to 50 mols/mol. When employing the preferred catalyst system, the mol ratio of the dialkylaluminum halide to the titanium trichloride complex usually ranges from 1.01002 to 1.0:50.0, preferably 1.0201 to 1.0:10.0. The amount of dialkylaluminum halide used is at least 1.0 10 gm./ gm. of monomer and can be as much as 25 1O gm./ gm. of monomer. The amount of titanium trichloride employed is generally in the range of 1.5x l to l0 gm./ gm. of monomer.

Although not essential to the conduct of the polymerization, it is often desirable to carry out the polymerization in the presence of elemental hydrogen. When so operating, hydrogen is added in an amount sufficient to provide from 0.03 to 1.0 mol percent hydrogen in the liquid mono-l-olefin phase in the polymerization zone.

Although pressures ranging from atmospheric up to 5000 p.s.i.g. can be used, a pressure in the range of 100 to 1000 p.s.i.g. is ordinarily preferred. In general, the pressure used in the process is sufiicient to maintain the reaction mixture substantially in the liquid phase.

The lower temperature used when ethylene is polymerized in the second step of the polymerization can be obtained by external heat exchange or by auto refrigeration, i.e., by flashing propylene from the first reaction mixture. A combination of these cooling methods can be used.

The proportion of the polypropylene and polyethylene portions of the product can be varied widely. Generally, the predominantly polyethylene portion constitutes 10 to 50, preferably to 25, percent by weight of the final product.

Several reactors can be used in either or both stages.

Although the ethylene can be added to reaction zone, in either liquid or gas phase, it is preferable in some instances to add to it in liquid phase.

Infrared spectra of the resin of this invention indicate that the copolymer phase contains methylene sequences of at least 5 or more units. There are two bands present at 13.70 and 13.88 microns, the former being a shoulder on the latter. The 13.70 micron band disappears when the sample is melted indicating that a crystalline polyethylene structure is present.

Examples of the best mode of operating according to my invention are set forth below. The examples are illustrative and should not be considered unduly limiting.

Example I Two runs were made in which propylene was polymerized in liquid phase in a l-gallon reactor for 2 hours at 120 F. in the presence of 44 ppm. hydrogen. In the first, the catalyst was obtained by mixing 0.59 grams of diethylaluminum chloride and 0.517 gram of 3TiCl .AlCl complex. The propylene was flashed off and one liter of liquid propylene and one pound (about one-half liter) of ethylene were added. The reaction was continued for 1 hour at 50 F. Approximately 292 grams of propylene polymerized in the first step and the final polymer weighed about 374 grams.

Run 2 was made following the same procedure with two changes. The amount of 3TiCl .AlCl complex was 0.494 gram. The second step, ethylene polymerization, was carried out for 3 hours at 0 F. Approximately 257 grams of propylene polymerized in the first step and the final product weighed about 321 grams.

Run Melt Brittleness Flexural Density Tensile N0. Index 1 Temp, Modulus, g./cc. p.s.i.

F 2 p.s.i.

1 ASTM Dl238-57T (230 F., 2160 g.).

3 ASTM D79061.

4 ASTM D1505-60T.

5 ASTM D63661T.

A series of runs were made to determine the amount of ethylene which will dissolve in propylene at various pressures and temperatures. The results at approximately 60 F. are pertinent in the data reported hereinafter. In each case liquid propylene was charged to an autoclave and ethylene pressured in. The mixture was agitated and, after momentarily stopping the agitation, a portion of the liquid was analyzed by mass spectrograph for mol percent ethylene.

Temp., Total M01 Percent Run F. Pressure, 07H; in p.s.i.g. Liquid These data provide the basis on which the mol percent C H figures are based in this and the following example.

Another preliminary series of runs was made to determine the rate of copolymer polymerization with varying amounts of ethylene in liquid propylene. All of these runs were made at 60 F. with no hydrogen present. The initiator components, diethylaluminum (DEAC) and aluminum activated titanium trichloride (AA TiCl having the approximate formula 3TiCl .AlCl were first added to the autoclave (3.82 liter capacity) followed by liquid propylene under its own vapor pressure. Ethylene was pressured in until the desired concentration was obtained in the liquid phase. The reaction was allowed to proceed for a specified period of time while maintaining a constant pressure on the system by continuous ethylene addition. The following results were obtained Data from these control runs were plotted and the plot used in determining the amount of copolymer in the following runs in which ethylene was polymerized in the presence of proylene followed by polymerization of propylene in the presence of liquid propylene.

In the following runs the ethylene was polymerized in the first stage, this corresponding to the above procedure. At the end of the desired ethylene polymerization, unreacted material (ethylene and propylene) was vented. For the second stage, based on 3.82 liter reaction volume, 0.08 gram mol of hydrogen was added in Runs 1-12 and 0.04 gram mol in Runs 13-15. The mixture was heated to 130 F. and propylene added until the reactor was liquid full. Propylene was added to maintain the reactor liquid full during the reaction, the time being varied according to the ratio of copolymer to homopolymer desired in the final product.

At the end of the run methanol was introduced to stop further reaction. Remaining liquid was flashed and the product weighted. Extraction With propylene produced an insoluble fraction upon which physical properties were determined. The following table summarizes these runs and shows the properties.

The preceding table illustrates the effect of ethylen concentration during the copolymerization stage and th efl'ect of copolymer concentration in the final produt in these resins. Low ethylene concentration in the reactc slurry and high copolymer concentration in the total poly mer both favored low brittleness temperature. Runs 13-1 show the effect of ethylene concentration upon reactio rates in the first stage. An increase in ethylene concentra tion from 1.5 ,to 40.5 percent decreased the reaction tim required to produce 17-19 weight percent copolymer from 5.6 to 0.87 hours. In these runs brittleness temperatur remained fairly constant but flexural modulus increase as ethylene concentration increased. While all of thee resins would be good for particular application, the data indicate that the best products have a copolymer conten in the range of 10 to 25 percent-low brittleness tempera ture and high impact strength.

Example III Except when differences are noted, the procedure 0: Example 11 was followed in a series of runs in which reaction temperature and hydrogen concentration (in the propylene homopolymerization) were varied. Using a 17.8

liter autoclave and an initiator formed by mixing 2 grams of aluminum activated TiCl and 2.39 grams of diethylaluminum chloride, ethylene was polymerized in the presence of propylene. The ethylene concentration was Stage 1 Stage 2 Total Polymer Properties of 0313 Insoluble Polymer Copoly- Impact 5 Tilz, Mol Rate, Rate, Producmer CaHo Flexural Tensile Brittle- Ungrams percent Time, g./g. AA' Time, lg. AA tivity, Content, Soluble, Modulus, Strength, ness notched 02H; hrs. TiCl hrs. T101 g./g. AA Wt. percent p.s.1. p.s.1. Temp, at 0 F., hr. hr. TiCl; percent XIO- F. it. 1P5] 1 ASTM D256-56. Z No break.

on reaction volume and given In gram mols. The data 3162 Stage 2 Total Polymer Properties of 0 11" Insoluble Polymer Run No. Rate, Produe- Co- CSHG Flexural Tensile Brittle- Impact,

Temp., Hi Moles Time, g./g. AA tivity, polymer Soluble, Modulus Strength, ness Unnotched F. Added Hours TiCh/hr. gJg. AA Content, percent p.s.1. 10- p.s.1. Temp., at 0 R,

TiCl; percent F. It. 1bs./1n.

110 0. 25 3. 17 226 906 21 3. 2 141 2, 833 31 17. 56 i: 110 o. 50 3. so 220 960 20 4. u 172 3, 047 24 12. 64 3 110 1. 00 3. 33 234 968 19 5. 3 192 2, 607 +30 3. 90 4 0. 25 1. 5 505 945 20 3. 7 134 2, 633 50 24. 79 5- 130 0.50 1. 5 506 1, 098 17 3. 8 163 3, 000 -20 10. 83 6. 130 1. 00 1. 5 584 1, 064 18 4. 5 184 2, 763 +41 4. 39 7- 0. 25 0. 88 883 965 20 4. 8 125 2, 627 50 25. 64 8- 150 0. 50 0.88 985 1, 055 18 4. 8 151 2, 870' 13 10. 11 9 150 1. 00 0. 88 1, 009 1, 076 18 7. 1 186 2, 973 0 4. 55

The data show that brittleness temperature and modulus crease with increase in hydrogen concentration. Brittle- :ss temperature was not greatly affected by an increase reaction temperature but modulus decreased in most 4. A polymerization process comprising polymerizing propylene in liquid propylene as a reaction medium in the presence of a catalyst formed by mixing material comprising (a) a compound having the formula R MX 1.865. wherein R is selected from the group consisting of alkyl, Example 1V cycloalkyl and aryl radicals, X is selected from the group Another series of runs included homopolymerization conslstmg of f m and a ilalogen 1S i l from E propylene followed by the production of the prethe group cfimslstmg of almpmum. f mdmm and ominantly ethylene copolymer. Following the initial l i n from 1 to mcluslYe m 15 from O to mpylene polymerization stage F for 2 hours; 2 inclusive, and the sum of m and r1 1s equal to the valence rams aluminum activated TiCl 2.39 grams dialkylof metal P hahde of a metal Selected luminum chloride), the reaction mixture was rapidly i f g i g i of metals of f ooled by flashing propylene from the reactor and by exo 4 at temperaturf t 6 range :rnal cooling to 60 F. Ethylene was added until the pres- 80.to 'addmg ethy1.ene. and contmumg polym' ure indicated the desired quantity in the propylene. Its i g i of hquld propylene at a .ow was regulated at this pressure to provide addition as ffi e OW 1 4 h f h lemanded by the reaction, the time being governed by the 1 6 Process 0 9 ere m a Por 1011 9 t e lesired ratio of copolymer to homopolymer in the prodhquld QP Teactlon medlum removed P to [CL A soluble fraction of the product Was removed by the addltlon OfthF Y vashing with an ethylene-propylene mixture. The etfect A P lym ri tion process comprising polyme izin 1f copolymer content is shown in the following table Propylene 111 llquld P py as r c on medlum 1n the vherein the copolymerization was carried out with 4.5 Presence 0f cfdtalyst Whlch forms 011 mixing y 1101 percent ethylene in the liquid propylene. aluminum chloride and 3TiCl .AlCl at 120 F. for 2 Stage 1 Stage 2 Total Polymer Properties of C2H4C3H Insoluble Polymer Run No. Hg Rate, Rate, Produe- Copolymer G2H4- Flexural Tensile Brittleness Impact Moles g./g. AA Time, g./g. AA tivity Content, 03H; Modulus, Strength, Temp, Unnot hed Added TiCh/hr. hrs. TiCh/hr. g./g AA Percent Soluble, p.s.1. 1l)- p.s.i. F. at 0 F.,

T1013 Percent it. lbs/in.

0. 10 332 Control 66 0 0 181 3, 760 +50 2 0. 10 332 0.67 so 717 7. 4 4. 6 184 3, 567 +12 7, 52 0. 10 332 2. 0 92 848 21. 7 4. 0 101 2, 35s 1 0. 10 332 4. 0 95 1, 059 37. 4 3. 5 48 4, 355 -72 0. 22 355 Control 710 0 0 216 4, 000 +80 2 0. 22 355 1. 0 87 797 10. 5 5.1 166 3, 313 -28 10. 29 0.22 355 2.0 95 900 20.8 4.9 124 2,533 -47 30. 54 0. 22 355 3. 0 92 985 27. 6 4. 7 95 4, 400 -57 0. 30 364 Control 727 U 0 220 4, 160 +100 2 0. 30 364 1.0 73 800 9.1 5. 5 214 3, 833 5. 37 0.30 364 2. 0 88 902 19. 4 5. 2 130 2, 500 32 22. 4s 0. 364 3. 0 84 980 25.8 4. 4 119 4, 733 -47 26. 44

1 No break.

As many possible embodiments can be made of this invention without departing from the scope thereof, it is to be understood that all matter herein set forth is to be interpreted as illustrative and not as unduly limiting the invention.

I claim:

1. A two-step polymerization process comprising a step in which propylene as the sole monomer is polymerized in the presence of liquid propylene in the absence of additional liquid diluent at a temperature within the range of 80 to 150 F. and a step in which ethylene is polymerized in the presence of liquid propylene in the absence of additional liquid diluent at a temperature within the range of -50 to 75 F., the step which is carried out second being performed in the presence of the polymer produced in the first, using a catalyst formed by mixing materials comprising (a) a compound having the formula R MX wherein R is selected from the group consisting of alkyl, cycloalkyl and aryl radicals, X is selected from the group consisting of hydrogen and a halogen, M is selected from the group consisting of aluminum, gallium, indium and thallium, n is from 1 to 3, inclusive, m is from 0 to 2, inclusive, and the sum of m and n is equal to the valence of the metal M, and (b) a halide 'of a metal selected from the group consisting of metals of Groups IV-A, IV-B, VB, Vl-B, and VIII.

2. The process of claim 1 wherein hydrogen is present during atleast one of said polymerization steps.

3. The process of claim 1 wherein hydrogen is present during the step in which propylene is the sole monomer present.

hours, cooling the resulting mixture of polypropylene and liquid propylene to 0 F., adding ethylene, and continuing polymerization in the presence of said liquid propylene for an additional 3 hours.

7. A polymerization process comprising polymerizing ethylene in the presence of liquid propylene in the absence of additional liquid diluent at a temperature within the range of 50 to 75 F., using a catalyst formed by mixing materials comprising (a) a compound having the formula R MX wherein R is selected from the group consisting of alkyl, cycloalkyl and aryl radicals, X is selected from the group consisting of hydrogen and a halogen, M is selected from the group consisting of aluminum, gallium, indium and thallium, n is from 1 to 3, inclusive, m is from 0 to 2, inclusive, and the sum of m and n is equal to the valence of the metal M, and (b) a halide of a metal selected from the group consisting of metal of Groups IVA, IV-B, V-B, VI-B and VIII removing unpolymerized ethylene from the reaction mixture, and polymerizing in the presence of liquid propylene at least a portion of the remaining propylene at a temperature within the range of to F. in the presence of the polymer produced in the first step.

8. The process of claim 7 wherein additional propylene is added to the reaction mixture following the removal of ethylene therefrom.

9. A polymerization process comprising preparing a polymer from a mixture of ethylene and propylene, said mixture containing approximately 1.5 to 40.5 mol percent of ethylene based on the mols of propylene at a temperature within the range of 50 to 75 F., in the 9 10 presence of a catalyst obtained by mixing 3TiC1 .A1Cl References Cited and diethylaluminum chloride, flashing ethylene from the FOREIGN PATENTS reaction mixture, adding additional propylene and con- 989 261 6/1962 Great Britain tinuing polymerization at a temperature within the range 915622 1/1963 Great Britain:

of 80 to 150 F., and recovering a final polymerization 5 1 220947 1/1960 France product, said final product containing approximately 15 to 25 percent by weight of the polymerization product JOSEPH L. SCHOFER, Primary Examiner. produced in the first step, both of said polymerizations B KURTZMAN, L. DENSON, being carried out in the presence of liquid propylene.

Assistant Examiners. 

1. A TWO-STEP POLYMERIZATION PROCESS COMPRISING A STEP IN WHICH PROPYLENE AS THE SOLE MONOMER IS POLYMERIZED IN THE PRESENCE OF LIQUID PROPYLENE IN THE ABSENCE OF ADDITIONAL LIQUID DILUENT AT A TEMPERATURE WITHIN THE RANGE OF 80 TO 150*F. AND A STEP IN WHICH ETHYLENE IS POLYMERIZED IN THE PRESENCE OF LIQUID PROPYLENE IN THE ABSENCE OF ADDITIONAL LIQUID DILUENT AT A TEMPERATURE WITHIN THE RANGE OF -50 TO 75*F., THE STEP WHICH IS CARRIED OUT SECOND BEING PERFORMED IN THE PRESENCE OF THE POLYMER PRODUCED IN THE FIRST, USING A CATALYST FORMED BY MIXING MATERIALS COMPRISING (A) A COMPOUND HAVING THE FORMULA RNMXM, WHEREIN R IS SELECTED FROM THE GROUP CONSISTING OF ALKYL, CYCLOALKYL AND ARYL RADICALS, X IS SELECTED FROM THE GROUP CONSISTING OF HYDROGEN AND A HALOGEN, M IS SELECTED FROM THE GROUP CONSISTING OF ALUMINUM, GALLIUM, INDIUM AND THALLIUM, N IS FROM 1 TO 3, INCLUSIVE, M IS FROM 0 TO 2, INCLUSIVE, AND THE SUM OF M AND N IS EQUAL TO THE VALENCE OF THE METAL M, AND (B) A HALIDE OF A METAL SELECTED FROM THE GROUP CONSISTING OF METALS OF GROUPS IV-A, IV-B, V-B,VI-B, AND VIII. 